Negatively sloped isolation structures

ABSTRACT

Negatively sloped isolation structures are formed on a semiconductor substrate to isolate devices from one another. The negatively sloped isolation structures have a top critical dimension which is smaller than a bottom critical dimension. The negatively sloped isolation structures may penetrate through an insulator layer of a silicon-on-insulator structure arrangement.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.16/009,450, entitled “Negatively Sloped Isolation Structures,” filed onJun. 15, 2018, which application is incorporated herein by reference.

BACKGROUND

The semiconductor industry has experienced rapid growth due tocontinuous improvements in the integration density of a variety ofelectronic components (e.g., transistors, diodes, resistors, capacitors,etc.). For the most part, this improvement in integration density hascome from repeated reductions in minimum feature size, which allows morecomponents to be integrated into a given area. As the demand for evensmaller electronic devices has grown recently, there has grown a needfor smaller and more creative packaging techniques of semiconductordies.

As the density of semiconductor technologies increases, the risk ofunwanted cross-talk between electronic components also increases. Assuch, there has grown a need for more creative ways to avoid noisecoupling of adjacent devices to maintain isolation while allowing forfabrication of smaller devices.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIGS. 1 through 7 illustrate cross-sectional views of intermediate stepsof the manufacture of a semiconductor device, in accordance with someembodiments.

FIGS. 8 through 16 illustrate cross-sectional views of intermediatesteps of the manufacture of a semiconductor device, in accordance withsome embodiments.

FIGS. 17 through 18 illustrate a device in an intermediate stage offormation, in accordance with some embodiments.

FIGS. 19 through 20 illustrate a device in an intermediate stage offormation, in accordance with some embodiments.

FIGS. 21 through 22 illustrate a device in an intermediate stage offormation, in accordance with some embodiments.

FIG. 23 illustrates a partial top down view of the devices of FIGS. 17,19, and 21, in accordance with some embodiments.

FIG. 24 illustrates a partial cross-section of a transistor device whichuses negatively sloped isolation structures, in accordance with someembodiments.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the invention. Specificexamples of components and arrangements are described below to simplifythe present disclosure. These are, of course, merely examples and arenot intended to be limiting. For example, the formation of a firstfeature over or on a second feature in the description that follows mayinclude embodiments in which the first and second features are formed indirect contact, and may also include embodiments in which additionalfeatures may be formed between the first and second features, such thatthe first and second features may not be in direct contact. In addition,the present disclosure may repeat reference numerals and/or letters inthe various examples. This repetition is for the purpose of simplicityand clarity and does not in itself dictate a relationship between thevarious embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Embodiments provide a negatively sloped isolation structure, such as ashallow trench isolation, between devices formed on a semiconductorsubstrate. In devices formed with positively sloped isolationstructures, as the isolation structure tapers into the substrate,adjacent devices get closer to each other. The negatively slopedisolation structures of the present embodiments allow devices to beformed closer together without increasing coupling effects and leakagefrom one device to another, or allow devices to be formed at the samecritical dimensions while improving isolation properties betweendevices. One application of the negatively sloped isolation structuresdescribed herein may be in radio frequency (RF) devices. Strongisolation may especially be important RF device applications, wheredevices are especially sensitive to close-talk (also referred to ascross-talk) from other nearby devices.

FIGS. 1 through 7 illustrate cross-sectional views of intermediate stepsof the manufacture of a semiconductor device, in accordance with someembodiments. FIG. 1 illustrates a substrate 102. Although the techniquesdescribed below are done so in terms of a silicon on insulator (SOI)arrangement, one of skill will understand that these techniques may beapplied to other substrate arrangements, such as a bulk semiconductor.

Substrate 102 may be a semiconductor substrate or glass substrate. Othersubstrates, such as a multi-layered or gradient substrate may also beused. Substrate 102 may be a wafer, such as a silicon wafer. Insulatorlayer 104 is formed over substrate 102 and may be, for example, a buriedoxide (BOX) layer, a silicon oxide layer, or the like. A topsemiconductor layer 106 is formed over insulator layer 104. Topsemiconductor layer 106 may be doped (e.g., with a p-type or an n-typedopant) or undoped. In some embodiments, the semiconductor material ofthe top semiconductor layer 106 may include silicon; germanium; acompound semiconductor including silicon carbide, gallium arsenic,gallium phosphide, indium phosphide, indium arsenide, and/or indiumantimonide; an alloy semiconductor including SiGe, GaAsP, AlInAs,AlGaAs, GaInAs, GaInP, and/or GaInAsP; combinations thereof; or thelike.

In some embodiments the material of top semiconductor layer 106 may bethe same as the material of substrate 102, while in other embodiments,the material of top semiconductor layer 106 may be different from thematerial of substrate 102. Insulator layer 104 may be formed by anysuitable means. For example, insulator layer 104 may be formed as aseparate layer on top of substrate 102 or may be formed by an oxidationtechnique, such as through ion beam implantation of oxygen followed by ahigh temperature annealing, or by oxidizing a semiconductor wafer andbonding the oxidized wafer to substrate 102.

In some embodiments, appropriate wells (not shown) may be formed in topsemiconductor layer 106. In some embodiments, where the resulting deviceis an n-type device, the wells are p-wells. In some embodiments, wherethe resulting device is a p-type device, the wells are n-wells. In otherembodiments, both p-wells and n-wells are formed in top semiconductorlayer 106. In some embodiments, p-type impurities are implanted into topsemiconductor layer 106 to form the p-wells. The p-type impurities maybe boron, BF₂, or the like, and may be implanted to a concentration ofequal to or less than 10¹⁸ cm⁻³, such as in a range from about 10¹⁷ cm⁻³to about 10¹⁸ cm⁻³. In some embodiments, n-type impurities are implantedinto top semiconductor layer 106 to form the n-wells. The n-typeimpurities may be phosphorus, arsenic, or the like, and may be implantedto a concentration of equal to or less than 10¹⁸ cm⁻³, such as in arange from about 10¹⁷ cm⁻³ to about 10¹⁸ cm⁻³. After implanting theappropriate impurities, an anneal may be performed on the substrate toactivate the p-type and n-type impurities that were implanted.

FIG. 2 illustrates the formation of a mask 108 over top semiconductorlayer 106. Mask 108 is used in a subsequent etching step to pattern thetop semiconductor layer 106 (see FIG. 3). In some embodiments, mask 108may comprise one or more mask layers. For example, in some embodiments,mask 108 may include a tri-layer or bi-layer mask having a topmost layerthat is photo-patternable. A bottommost layer of mask layer 108 may be ahard mask layer comprising silicon oxide, silicon nitride, siliconoxynitride, silicon carbide, silicon carbonitride, a combinationthereof, or the like, and may be formed using any suitable process, suchas thermal oxidation, thermal nitridation, atomic layer deposition(ALD), physical vapor deposition (PVD), chemical vapor deposition (CVD),a combination thereof, or the like. The bottommost layer of mask 108 maybe used to prevent or minimize etching of the top semiconductor layer106 underlying the bottommost layer of mask 108 in the subsequent etchstep (see FIG. 3). The topmost layer of mask 108 may comprisephotoresist, and in some embodiments, may be used to pattern thebottommost layer of mask 108 for use in the subsequent etching step. Thetopmost layer of mask 108 may be formed by using a spin-on technique andmay be patterned using acceptable photolithography techniques. In someembodiments, the mask 108 may comprise additional mask layers.

Mask 108 is patterned to provide a patterned mask 12 and openings 14 byone or more patterning processes 16. Openings 14 correspond to areas oftop semiconductor layer 106 in which an isolation structure will beformed. Patterned mask 12 remains to mask top semiconductor layer 106from etching processes which will form trenches in top semiconductorlayer 106. Patterning processes 16 may include combinations ofphoto-patterning processes and etching processes, depending on thematerials and layer composition of mask 108, as discussed above. Forexample, to form openings in a topmost photo-patternable layer of mask108, a photo-patterning process may be used. Next, an etching processmay be used to extend the pattern of the openings in the topmost layerto a subsequent layer, while using the topmost layer as a mask toprotect the portions of the subsequent layer that should not be etched.Patterning processes 16 may be chosen to be selective to the materialsbeing patterned, such that little to no over patterning occurs.

Referring now to FIG. 3, FIG. 3 illustrates the formation of deviceregions 22 in the top semiconductor layer 106. An etching process 26 isperformed using patterned mask 12 (see FIG. 2) as a mask to transfer thepattern of patterned mask 12 to the underlying top semiconductor layer106. Openings 14 (see FIG. 2) are extended to create trenches 24. Theetching may be done by any acceptable etch process, such as a reactiveion etch (RIE), neutral beam etch (NBE), a combination thereof, or thelike. The etch process may be anisotropic.

In some embodiments, etching process 26 may include a tuned etch toprovide trenches 24 in the top semiconductor layer 106 which arenegatively sloped. In such embodiments, for example, the etching may bea dry etch with parameters tuned to achieve negatively sloped trenches24. For example, selection of process gasses, etch time, chamberpressure, flow rate of process gasses, temperature, plasma source power,and bias power may be adjusted as needed to provide an etch result whichproduces a trench having a larger bottom dimension (e.g., d₂, discussedbelow) than top dimension (e.g., d₁, discussed below). In someembodiments, etching process 26 may include an etch time between about20 sec and about 60 sec, such as about 35 sec, a pressure between about3 mTorr and about 45 mTorr, such as about 8 mTorr, a flow rate of theprocess gas between about 20 sccm and about 800 sccm, such as about 60sccm, a temperature between about 15° C. and about 65° C., such as about30° C., a source power between about 500 Watts and about 700 Watts, anda bias power (which may be applied to the chuck of the respectiveetching tool) between about 100 V and about 500 V, such as about 300 V.These include mere example values and ranges. Other values may be usedwithout limitation to achieve a particular desired etch profile. Thevalues will also be based at least in part on the etchant selected. Anysuitable etchant may be used which is selective to the material of topsemiconductor layer 106. For example, in some embodiments the processgases may include an etchant which is oxygen based, nitrogen based,hydrogen based, fluorine based, or chlorine based, or combinationsthereof. For example, such process gases may include one or more of O₂,N₂, H₂, CF₄, NF₃, NH₃, or Cl₂. Other suitable etchant gasses may beused. In addition, other process or mix gasses may be used.

In some embodiments, etching process 26 may include multiple etchprocesses. For example, in some embodiments a dry etch may be performedfollowed by a wet etch. The dry etch may be a tuned etch, similar tothat described above, or may be an anisotropic etch, or another suitableetch. The etchant gasses may be selected from the same list of etchantgases described above. The wet etch may use a chemical including afluorine-containing species and metal inhibitors, such as a diluted HFetch. The dry etch may produce trenches having sidewalls which arenegatively sloped, substantially vertical, or positively sloped. The wetetch may expand the trench to produce sidewalls which are negativelysloped.

In some embodiments, etching process 26 may result in trenches 24extending into the insulator layer 104. In some embodiments, trenches 24may not extend into the insulator layer 104. During etching process 26,insulator layer 104 may be used as an etch stop and a subsequent etchmay break through insulator layer 104 by removing some material ofinsulator 104 so that trenches 24 extend into insulator layer 104. Insome embodiments, etching process 26 may partially etch insulator 104 ina single dry etch step or in a combined dry etch step followed by a wetetch step, depending on process gasses and etching chemicals selected.In some embodiments, trenches 24 may extend into insulator layer 104 bya distance of about 5 nm to about 60 nm, such as about 30 nm.

Etching process 26 produces trenches 24 having negatively slopedsidewalls. That is, trenches 24 may taper from bottom to top orconversely flare from top to bottom such that the openings of thetrenches 24 are narrower at the top of trenches 24 than at the bottom oftrenches 24. Where the sidewalls are negatively sloped, the angle β₁ ofthe sidewalls of trenches 24 is less than 90° from the bottom horizontalsurface of trenches 24. Conversely, the angle α₁ of the sidewalls oftrenches to a horizontal line across the top of trenches 24 is greaterthan 90°. For example in some embodiments the angle α₁ may be betweengreater than 90° and 135°, such as about 110° and the angle β₁ may bebetween about 65° up to less than 90°, such as about 80°.

Trenches 24 have a dimension d₁ at the top of trenches 24 between about80 nm and 500 nm, such as about 220 nm. In some embodiments thedimension d₁ may be greater than 500 nm. The dimension d₂ at the bottomof trenches 24 may be such that a ratio of d₁:d₂ is between about 0.6and 0.95, such as about 0.85. Other dimensions may be used. Each trenchof trenches 24 may be individually formed and designed according to adesired layout, such that one trench may have different dimensions thananother trench. Trenches 24 also have a length aspect, which isillustrated below with respect to FIG. 23. The lengths may vary greatlyaccording to design layout. The dimension d₁ corresponds to a topcritical dimension (TCD) of isolation structures deposited withintrenches 24 and the dimension d₂ corresponds to a bottom criticaldimension (BCD) of the isolation structures deposited within trenches24. Because of the negatively sloped sidewalls of trenches 24, the TCDof trenches 24 is less than the BCD of trenches 24, which can providebetter isolation in the subsequently formed isolation structures than ifthe BCD were less than the TCD, such as in typical isolation structures.Alternatively, the TCD of the device may be reduced while maintainingthe same or better effective isolation provided by the subsequentlyformed isolation structures. For example, the BCD of a typical devicemay be used as the TCD of a device using the negatively sloped sidewallsas discussed herein.

Referring now to FIG. 4, FIG. 4 illustrates the deposition of aninsulation material in trenches 24 through a deposition process 36 toform isolation structures 110. The insulation material may be an oxide,such as silicon oxide, a nitride, such as silicon nitride, the like, ora combination thereof, and may be formed by a high density plasmachemical vapor deposition (HDP-CVD), a flowable CVD (FCVD) (e.g., aCVD-based material deposition in a remote plasma system and post curingto make it convert to another material, such as an oxide), a combinationthereof, or the like. Other insulation materials formed by anyacceptable processes may be also used.

In some embodiments, the isolation structures 110 may include aconformal liner (not illustrated) formed on sidewalls and bottomsurfaces of trenches 24 (see FIG. 3) prior to filling trenches 24 withan insulation material of the isolation structures 110. In someembodiments, the liner may comprise a semiconductor (e.g., silicon)nitride, a semiconductor (e.g., silicon) oxide, a thermal semiconductor(e.g., silicon) oxide, a semiconductor (e.g., silicon) oxynitride,combinations thereof, or the like. The formation of the liner mayinclude any suitable method, such as ALD, CVD, HDP-CVD, PVD, acombination thereof, or the like. In such embodiments, the liner mayprevent (or at least reduce) the diffusion of the semiconductor materialfrom the device regions 22 of the top semiconductor layer 106 (e.g., Siand/or Ge) into the surrounding isolation structures 110 during thesubsequent annealing of the isolation structures 110. In someembodiments, after the insulation material of the isolation structures110 are deposited, an annealing process may be performed on theinsulation material of the isolation structures 110.

In some embodiments, as illustrated in FIG. 4, top surfaces of isolationstructures 110 may protrude from the top semiconductor layer 106 suchthat their top surfaces are higher than the top surfaces of the deviceregions 22 of top semiconductor layer 106. In some embodiments, aplanarization process (see, e.g., FIG. 17), such as a chemicalmechanical polishing (CMP), may remove any excess insulation material ofthe isolation structures 110, such that top surfaces of isolationstructures 110 and top surfaces of the device regions 22 of topsemiconductor layer 106 are substantially level (or coplanar).

FIGS. 5 through 7 illustrate the formation of deeper trenches andsubsequently taller isolation structures. In embodiments consistent withFIGS. 5 and 6, an isolation structure is formed which completelytraverses through insulator layer 104. In some embodiments, theisolation structure can penetrate into substrate 102. In embodimentsconsistent with FIGS. 5 and 7, an isolation structure is formed which issimilar to the isolation structure in FIG. 6, but because of the highaspect ratio and differences in TCD and BCD in the trenches, an air gapis formed embedded in the isolation structure, further improvingisolation characteristics.

Referring to FIG. 5, FIG. 5 illustrates a process where trenches 24 (seeFIG. 3) are further recessed into and through insulator layer 104 andinto substrate 102. The trenches 24 are further recessed to formtrenches 44 by etching process 46. Etching process 46 may include one ormore etch steps to first etch insulator layer 104, using substrate 102as an etch stop. A subsequent etch may further recess trenches 44 intosubstrate 102. In some embodiments, trenches 44 may not extend intosubstrate 102. In some embodiments, a separate etch stop (not shown) maybe provided between insulator layer 104 and substrate 102 to assist incontrolling etching process 46. Similar to etching process 26, etchingprocess 46 may include a dry etch followed by a wet etch. In someembodiments, etching process 26 and 46 may be combined to perform thedry etch of etching process 26 and etching process 46 followed by thewet etch of etching process 26 and etching process 46. In someembodiments, one of the wet etches of etching process 26 and etchingprocess 46 may be omitted.

Etching process 46 produces trenches 44 having negatively slopedsidewalls. That is, trenches 44 may taper from bottom to top orconversely flare from top to bottom such that the openings of thetrenches 44 are narrower at the top of trenches 44 than at the bottom oftrenches 44. Where the sidewalls are negatively sloped, the angle β₂ ofthe sidewalls of trenches 44 is less than 90° from the bottom horizontalsurface of trenches 44. Conversely, the angle α₂ of the sidewalls oftrenches to a horizontal line across the top of trenches 44 is greaterthan 90°. For example in some embodiments the angle α₂ may be betweengreater than 90° and 135°, such as about 110° and the angle β₂ may bebetween about 60° up to less than 90°, such as about 80°.

Trenches 44 have a dimension d₃ at the top of trenches 44 between about80 nm and 500 nm, such as about 220 nm. In some embodiments thedimension d₃ may be greater than 500 nm. The dimension d₄ at the bottomof trenches 44 may be such that a ratio of d₃:d₄ is between about 0.6and 0.95, such as about 0.85. Other dimensions may be used. Each trenchof trenches 44 may be individually formed and designed according to adesired layout, such that one trench may have different dimensions thananother trench. Trenches 44 also have a length aspect, which is shownbelow with respect to FIG. 23. The dimension d₃ corresponds to a TCD ofisolation structures deposited within trenches 44 and the dimension d₄corresponds to a BCD of the isolation structures deposited withintrenches 44. Because of the negatively sloped sidewalls of trenches 44,the TCD of trenches 44 is less than the BCD of trenches 44.

Referring now to FIG. 6, FIG. 6 illustrates the deposition of aninsulation material in trenches 44 (see FIG. 5) through a depositionprocess 56 to form isolation structures 210. Materials and processesused to deposit the insulation material of isolation structures 210 maybe similar to those discussed above with respect to isolation structures110 and are not repeated.

Referring back to FIGS. 3 and 5, the depth of trenches 24 or trenches 44may be between about 50 nm and about 500 nm, such as about 100 nm fortrenches 24 or 300 nm for trenches 44, as measured from the top of theopening of the trench to the bottom of the trench. In some embodiments,an aspect ratio of the depth of trenches 24 or trenches 44 to the TCD oftrenches 24 or TCD of trenches 44 may be between about 0.5 and 10, suchas about 2.

Referring now to FIG. 7, FIG. 7 illustrates the deposition of aninsulation material in trenches 44 (see FIG. 5) through a depositionprocess 66 to form isolation structures 310. When the aspect ratio ofthe depth of trenches 44 (see FIG. 5) to the TCD of trenches 44 isgreater than about 4 and less than or equal to about 10, an air gap 130may be formed within isolation structures 310. Air gap 130 providesfurther isolation strength and further reduced device close-talk betweendevices formed in adjacent or nearby device regions 22.

Air gap 130 may have a shape which flares in manner similar to thesidewalls of isolation structure 310, having a narrower top and a widerbottom. Air gap 130 will form depending on deposition process 66 of theinsulation material of isolation structures 310. For example, in someembodiments deposition of insulation material may conformally (withinprocess variations) form on the bottom and sidewalls of trenches 44until the top of air gap 130 is pinched off from further formationwithin the space of air gap 130. The resulting shape of air gap 130 mayhave a curved or flat bottom and come to a point at a top extent of airgap 130. Air gap 130 may be embedded in isolation structure 310 suchthat its sidewalls are substantially equidistant from the interfacebetween isolation structure 310 and device region 22 and betweenisolation structure 310 and the underlying insulator layer 104 of deviceregion 22.

Air gap 130 may have a height between about 30% to about 80% of thetrench 44 height, such as about 50% of the height of trenches 44. Airgap 130 may have a largest width W₁ (toward the bottom of the air gap)between about 20% and 80% of the BCD of trenches 44. At the point whereair gap 130 is widest, the minimum distance d₅ from air gap 130 to thesidewall of isolation structure 310 may be between about 10% and about40% of the trench CD (or width) W₂ at that location. This may also beunderstood as the thickness of the insulation material of isolationstructure 310 wall.

As illustrated in FIG. 7, in some embodiments, air gap 130 may extendinto top semiconductor layer 106 or into substrate 102. In someembodiments, air gap 130 may only be disposed in insulator layer 104 ormay only be disposed in substrate 102 or may only be disposed in bothinsulator layer 104 and substrate 102, but not top semiconductor layer106.

FIGS. 8 through 16 illustrate cross-sectional views of intermediatesteps of the manufacture of a semiconductor device, in accordance withsome embodiments. FIGS. 8 through 16 illustrate embodiments whereisolation structures having negatively sloped sidewalls are formed aswell as isolation structures having non-negatively (e.g., positively)sloped sidewalls.

FIG. 8 illustrates the formation of a tri-layer mask 109 over patternedmask 12. Tri-layer mask 109 comprises a bottom layer 109A, a middlelayer 109B over the bottom layer 109A, and a top layer 109C over themiddle layer 109B. In some embodiments, the bottom layer 109A maycomprise an organic material, such as a spin-on carbon (SOC) material,or the like, and may be formed using spin-on coating, CVD, ALD, or thelike. The middle layer 109B may comprise an inorganic material, whichmay be a nitride (such as SiN, TiN, TaN, or the like), an oxynitride(such as SiON), an oxide (such as silicon oxide), or the like, and maybe formed using CVD, ALD, or the like. The top layer 109C may comprisean organic material, such as a photoresist material, and may be formedusing a spin-on coating, or the like. In some embodiments, the top layer109C of the tri-layer mask 109 is patterned using suitablephotolithography techniques to expose a portion of the middle layer109B, which is subsequently etched using the top layer 109C as a mask.

FIG. 9 illustrates the removal of portions of the bottom layer 109A oftri-layer mask 109. Middle layer 109B is used as a mask to protect otherportions of bottom layer 109A that should not be removed. In the removalof the portions of the bottom layer 109A, the top layer 109C may beconsumed. The removal of the portions of the bottom layer 109A exposespart of the patterned mask 12 and corresponding openings 14 formedtherein.

FIG. 10 illustrates the etching of trenches 24 having negatively slopedsidewall by etching process 26, such as described above with respect toFIG. 3, which is not repeated. During etching process 26, the bottomlayer 109A protects the portions of top semiconductor layer 106 whichare not etched to form trenches.

Referring now to FIG. 11, the bottom layer 109A is removed by anysuitable technique and another tri-layer mask 111 is formed overpatterned mask 12. Tri-layer mask 111 is similar to tri-layer mask 109and may be formed using the same processes and materials as describedabove with respect to tri-layer mask 109, which are not repeated. Thetop layer 111C of tri-layer mask 111 may be patterned to expose portionsof the middle layer 111B, which is subsequently etched using the toplayer 111C as a mask.

FIG. 12 illustrates the removal of portions of the bottom layer 111A oftri-layer mask 111. Middle layer 111B is used as a mask to protect otherportions of bottom layer 111A that should not be removed. In the removalof the portions of the bottom layer 111A, the top layer 111C may beconsumed. The removal of the portions of the bottom layer 111A exposespart of the patterned mask 12 and corresponding openings 14 formedtherein.

Referring now to FIG. 13, FIG. 13 illustrates the etching of trenches 25having non-negative (e.g., positive) sloped sidewalls by etching process27. Etching process 27 may include any suitable etching process, such asa dry or wet etch using suitable etchants, which are selective to thematerial of top semiconductor layer 106. Etching process 27 may includemultiple etching steps. For example, a first etch may form trenches 25to insulator layer 104 and a subsequent etch may break through theinsulator layer 104 to extend trenches 25 into insulator layer 104.Trenches 25 may extend into insulator layer 104 by a depth of 5 nm toabout 60 nm, such as about 30 nm. In some embodiments, trenches 25 maynot extend into insulator layer 104. Isolation structures havingnon-negative (e.g., positive) sloped sidewalls will be formed intrenches 25 on either side of device region 23.

Referring now to FIG. 14, FIG. 14 illustrates the formation of isolationstructures 110 and isolation structures 112. Tri-layer mask 111 isremoved using any suitable process. Subsequently, insulation materialmay be deposited in trenches 24 and trenches 25 (see FIGS. 10 and 13)through a deposition process to form isolation structures 110 andisolation structures 112. Materials and processes used to deposit theinsulation material of isolation structures 110 and isolation structures112 may be similar to those discussed above with respect to isolationstructures 110 of FIG. 4 and are not repeated. The resulting isolationstructures 110 have negatively sloped sidewalls, while the resultingisolation structures 112 have non-negatively sloped sidewalls (e.g.,positively sloped sidewalls). In this way, different types of isolationstructures may be formed for different devices on one wafer.

FIGS. 15 and 16 illustrate counterparts to the formation of isolationstructures 110 of FIG. 14. FIG. 15 illustrates a counterpart of FIG. 14where isolation structure 210 of FIG. 6 is formed by modifying theprocess in FIGS. 8-14 to further recess the trenches such as illustratedin FIG. 5. FIG. 16 illustrates a counterpart of FIG. 14 where isolationstructure 310 of FIG. 7 is formed by modifying the process in FIGS. 8-14to further recess the trenches such as illustrated in FIG. 5 and formingan isolation structure having an air gap embedded therein. Theseembodiments are described in more detail below.

FIG. 15 illustrates isolation structures 210 and isolation structures212, in accordance with some embodiments. Isolation structures 210 arenegatively sloped isolation structures such as discussed above withrespect to isolation structures 210 of FIG. 6. Isolation structures 212are non-negatively sloped isolation structures which may be formed bycombining the techniques discussed above with respect to FIGS. 8-14 andthe techniques discussed with respect to FIG. 6 to further recess thetrenches 44 through insulator layer 104. Similarly, etch process 27 (seeFIG. 13) may be modified to also further recess the trenches 25 of FIG.13 through insulator layer 104. In some embodiments, the trenches may befurther recessed to also break through substrate 102.

The isolation structures 210 and 212 are formed in the resultingtrenches by the deposition of insulation material through a depositionprocess using materials and processes similar to those discussed abovewith respect to FIG. 4 and are not repeated.

FIG. 16 illustrates isolation structures 310 and isolation structures212, in accordance with some embodiments. Isolation structures 310 arenegatively sloped isolation structures such as discussed above withrespect to isolation structures 310 of FIG. 7. Isolation structures 310have air gaps 130 formed therein. Isolation structures 212 arenon-negatively sloped isolation structures which may be formed in amanner similar to that discussed above with respect to FIG. 15. Becausethe TCD of isolation structures 212 is greater than the BCD of isolationstructures 212, an air gap will not form in the trench corresponding toisolation structure 212. However, because the TCD of isolationstructures 310 is smaller than the BCD of isolation structures 310, anair gap 130 may be formed therein, such as discussed above with respectto FIG. 7.

Although the process described in FIGS. 8-16 are described in aparticular order, one of skill will understand that the steps may havebeen performed in another order. For example, referring to FIG. 14,trenches for isolation structure 112 may be formed prior to trenches forisolation structure 110. Also, in some embodiments, isolation structure112 and isolation structure 110 may be completely formed independently,leaving a respective bottom layer 109A or 111A in place while theisolation structure 110 or 112 is completely formed. Other orders may beused as appropriate.

In some embodiments, the techniques described above with respect toFIGS. 1-16 may be mixed to achieve different isolation structures ofdifferent depths and different sidewall slopes.

FIGS. 17 through 18 illustrate a device in an intermediate stage offormation, in accordance with some embodiments. The isolation structures110 of FIG. 17 may be formed according to the processes discussed abovewith respect to FIGS. 1-5.

Resulting device regions 22 between adjacent isolation structures 110may be tapered inverse to the shape of the isolation structures 110. Atop angle γ₁ of device region 22, measured from a top surface of deviceregion 22 to a side wall of device region 22, may be less than 90°, suchas between about 65° and 90°. A bottom angle δ₁ of device region 22,measured from a bottom surface of device region 22 to a side wall ofdevice region 22 may be greater than 90°, such as between about 90° and135°. Other angles may be used. A width d₆ of device region 22 at a TCDof device region 22 may be between about 100 nm and 400 nm. A width d₇of device region at a BCD of device region 22 may be between about 65 nmand 300 nm. Other dimensions greater or less than these may be used. TheTCD of device region 22 is greater than the BCD of device region 22. Theratio of TCD to BCD of device region 22 may be between about 1.05 and1.5.

Following the formation of isolation structures 110, devices may beformed in device region 22 (see FIG. 5). For example, a transistor 120may be formed to create a channel region 122 in device region 22.Source/drain regions 124 and a gate structure including a gate electrode128 and gate spacer 126 may be formed using suitable techniques.

In some embodiments, a dummy gate may be formed and later replaced witha replacement gate. For example, a dummy gate may be formed bydepositing a dummy gate dielectric layer and dummy gate electrode layer.The gate dielectric layer and dummy gate electrode layer may bepatterned to form a dummy gate structure. A spacer layer may bedeposited over the dummy gate structure and anisotropically etched toleave vertical portions of the spacer layer, resulting in gate spacers126.

Source/drain regions 124 may be formed by using the dummy gate to defineimplantation regions, where p-type or n-type dopants may be implanted,depending on the type of device. In some embodiments, recesses may beetched next to the dummy gate and doped or undoped source/drain regions124 epitaxially grown therein.

In embodiments using a dummy gate, a replacement gate process may beperformed to replace the dummy gate with a permanent gate, such as ametal gate. An etch stop layer (not shown) and an interlayer dielectric(ILD) (not shown) are deposited over the dummy gates, and over thesource/drain regions 124. In some embodiments, the ILD may be a flowablefilm formed by a flowable CVD. In some embodiments, the ILD may beformed of a dielectric material such as Phospho-Silicate Glass (PSG),Boro-Silicate Glass (BSG), Boron-Doped Phospho-Silicate Glass (BPSG),undoped Silicate Glass (USG), or the like, and may be deposited by anysuitable deposition method, such as CVD, PECVD, a combination thereof,or the like. In some embodiments, the etch stop layer is used as a stoplayer while patterning the ILD to form openings for subsequently formedcontacts. Accordingly, a material for the etch stop layer may be chosensuch that the material of the etch stop layer has a lower etch rate thanthe material of ILD.

A planarization process, such as a CMP, may be performed to level thetop surface of ILD with the top surfaces of the dummy gates, exposingthe dummy gates. Recesses are made in the dummy gates, removing thedummy gate electrode and optionally the dummy gate dielectric, exposingan underlying channel region.

Gate dielectric layers (see gate dielectric 129 of FIG. 24), and gateelectrodes 128 are formed in the recesses made in the dummy gates. Insome embodiments, the gate dielectric layers comprise silicon oxide,silicon nitride, or multilayers thereof. In other embodiments, the gatedielectric layers include a high-k dielectric material, and in theseembodiments, the gate dielectric layers may have a k value greater thanabout 7.0, and may include a metal oxide or a silicate of Hf, Al, Zr,La, Mg, Ba, Ti, Pb, and combinations thereof. The formation methods ofthe gate dielectric layers may include Molecular-Beam Deposition (MBD),ALD, CVD, PECVD, a combination thereof, or the like. In someembodiments, the formation may result in a conformally deposited layerwith horizontal portions and vertical (or non-horizontal) portionshaving substantially the same thickness, for example, with the verticalthickness of the vertical portions of the gate dielectric layers and thehorizontal thickness of the horizontal portions of the gate dielectriclayers having a difference smaller than 20 percent. In some embodiments,the gate dielectric layers may be thermally grown.

Next, the gate electrodes 128 are deposited over the gate dielectriclayers and fill the remaining portions of the recesses of the dummygates. The gate electrodes 128 may be made of a metal-containingmaterial such as TiN, TaN, TaC, TiC, TiO, Co, Ru, Al, Ag, Au, W, Ni, Ti,Cu, combinations thereof, or multi-layers thereof. After the filling ofthe gate electrodes, a planarization process, such as a CMP, may beperformed to remove the excess portions of the gate dielectric layers,and the gate electrodes 128, which excess portions are over the topsurface of the ILD. The gate electrodes 128 may include a series of oneor more stacked layers (not shown). The stacked layers may include adiffusion barrier layer and one or more work function layers over thediffusion barrier layer. The diffusion barrier layer may be formed oftitanium nitride (TiN) or thallium nitride. The work function layer(s)determine the work function of the gate, and may include at least onelayer, or a plurality of layers formed of different materials. Thespecific material of the work function layer may be selected accordingto the type of transistor 120 being formed. For example, when thetransistor 120 is an n-type, the work function layer may include anAlTiC layer. When the transistor 120 is a p-type, the work functionlayer may include an AlTiN and/or AlTiC layer. After the deposition ofthe work function layer(s), a barrier layer (not shown), which may beanother TiN layer, may be formed.

Referring again to FIG. 17, λ₁, λ₂, λ₃, and λ₄ each represent close-talkor cross-talk effects. λ₁, for example, may include a capacitancecoupling through the isolation structure 110 at a TCD of the isolationstructure 110. λ₂ may include a capacitance coupling through theisolation structure 110 at a BCD of the isolation structure 110. Whereasin an isolation structure with positively sloped sidewalls thecapacitance coupling in λ₂ would be greater than the capacitancecoupling in λ₁, because the TCD of the negatively sloped isolationstructure 110 is smaller than the BCD of the isolation structure, thecapacitance coupling in λ₂ is lower than in λ₁. Thus, noise added byincreased capacitance coupling in a typical isolation structure may beavoided by using a negatively sloped isolation structure 110. Similarly,λ₃ and λ₄ may include a capacitance coupling through insulator layer 104and through substrate 102, respectively.

Each of λ₁, λ₂, λ₃, and λ₄ may also include a resistive aspect ofclose-talk or cross-talk effects where lower resistance results in agreater leakage effect from one device to another device. Whereas in anisolation structure with positively sloped sidewalls the resistiveleakage in λ₂ would be greater than the resistive leakage in λ₁, becausethe TCD of the negatively sloped isolation structure 110 is smaller thanthe BCD of the isolation structure, the resistive leakage in λ₂ is lowerthan in λ₁.

Referring to FIG. 18, a perspective view of the device of FIG. 17 isillustrated, in accordance with some embodiments. Devices such astransistor 120 are formed in a top semiconductor layer 106 and areseparated by isolation structures 110 having negatively sloped sidewalls. Isolation structures 110 may be used in place of positivelysloped isolation structures without negatively impacting channel lengthor other aspects of transistor 120. A more effective isolation structureis therefore achieved. Because the TCD of the isolation structure 110may be the same as the TCD of a typically used isolation structure, again in isolation strength can be achieved in the same criticaldimension of the active devices 120. Isolation strength increases asdepth into the isolation structure 110 increases.

Referring to FIGS. 19 and 20, FIGS. 19 and 20 illustrate a device in anintermediate stage of formation, in accordance with some embodiments.The isolation structures 210 of FIG. 19 may be formed according to theprocesses discussed above with respect to FIG. 6.

Resulting device regions 22 between adjacent isolation structures 210may be tapered inverse to the shape of the isolation structures 210. Atop angle γ₂ of device region 22, measured from a top surface of deviceregion 22 to a side wall of device region 22, may be less than 90°, suchas between about 65° and 90°. A bottom angle δ₂ of device region 22,measured from a bottom surface of device region 22 to a side wall ofdevice region 22 may be greater than 90°, such as between about 90° and135°. Other angles may be used. A width d₈ of device region 22 at a TCDof device region 22 may be between about 100 nm and 400 nm. A width d₉of device region at a BCD of device region 22 may be between about 65 nmand 300 nm. Other dimensions greater or less than these may be used. TheTCD of device region 22 is greater than the BCD of device region 22. Theratio of TCD to BCD of device region 22 may be between about 1.05 and1.5.

Subsequently, devices, such as transistor 120, may be formed in thedevice regions 22 of top semiconductor layer 106, resulting in channelregions 122 of transistor 120. Transistor 120 may be formed in a mannerand with materials similar to those discussed above with respect to FIG.17.

Similar to that discussed above with respect to FIG. 17, λ₁, λ₂, λ₃, andλ₄ of FIG. 19 each represent close-talk or cross-talk effects atdifferent areas of the isolation structure 210. λ₁ includes close-talkeffects, such as capacitance coupling and resistive leakage, at the TCDof isolation structure 210. λ₂ includes close-talk effects at amid-portion of isolation structure 210. λ₃ includes close-talk effectsat a BCD of isolation structure 210. λ₄ includes close-talk effectsthrough substrate 102. Because the BCD of isolation structure 210 isgreater than the TCD, the close-talk effects decrease the deeper intoisolation structure. In contrast, in a positively-sloped isolationstructure, the close-talk effects increase as the isolation structuretapers, causing the device area of neighboring devices to become closerto each other.

Referring to FIG. 20, a perspective view of the device of FIG. 19 isillustrated, in accordance with some embodiments. Devices such astransistor 120 are formed in a top semiconductor layer 106 and areseparated by isolation structures 210 having negatively sloped sidewalls. Isolation structures 210 may be used in place of positivelysloped isolation structures without negatively impacting channel lengthor other aspects of transistor 120. A more effective isolation structureis therefore achieved. Because the TCD of the isolation structure 210may be the same as the TCD of a typically used isolation structure, again in isolation strength can be achieved in the same criticaldimension of the active devices 120. Isolation strength increases asdepth into the isolation structure 210 increases.

Referring to FIGS. 21 and 22, FIGS. 21 and 22 illustrate a device in anintermediate stage of formation, in accordance with some embodiments.The isolation structures 310 of FIG. 21 may be formed according to theprocesses discussed above with respect to FIG. 7.

Resulting device regions 22 between adjacent isolation structures 210may be tapered inverse to the shape of the isolation structures 210. Atop angle γ₃ of device region 22, measured from a top surface of deviceregion 22 to a side wall of device region 22, may be less than 90°, suchas between about 65° and 90°. A bottom angle δ₃ of device region 22,measured from a bottom surface of device region 22 to a side wall ofdevice region 22 may be greater than 90°, such as between about 90° and135°. Other angles may be used. A width d₁₀ of device region 22 at a TCDof device region 22 may be between about 100 nm and 400 nm. A width d₁₁of device region at a BCD of device region 22 may be between about 65 nmand 300 nm. Other dimensions greater or less than these may be used. TheTCD of device region 22 is greater than the BCD of device region 22. Theratio of TCD to BCD of device region 22 may be between about 1.05 and1.5.

Subsequently, devices, such as transistor 120, may be formed in thedevice region 22 of top semiconductor layer 106, resulting in channelregion 122 of transistor 120. Transistor 120 may be formed in a mannerand with materials similar to those discussed above with respect to FIG.17.

Similar to that discussed above with respect to FIG. 17, λ₁, λ₂, λ₃, andλ₄ of FIG. 21 each represent close-talk or cross-talk effects atdifferent areas of the isolation structure 310. λ₁ includes close-talkeffects, such as capacitance coupling and resistive leakage, at the TCDof isolation structure 310. λ₂ includes close-talk effects at amid-portion of isolation structure 310. λ₃ includes close-talk effectsat a BCD of isolation structure 310. λ₄ includes close-talk effectsthrough substrate 102. Because the BCD of isolation structure 310 isgreater than the TCD, the close-talk effects decrease the deeper intoisolation structure. In contrast, in a positively-sloped isolationstructure, the close-talk effects increase as the isolation structuretapers, causing the device area of neighboring devices to become closerto each other. Moreover, air gaps 130 further inhibit close-talk effectscausing a resistive leakage path through isolation structure 310 toincrease disproportionately in length, thereby increasing resistance andcorrespondingly decreasing leakage. In contrast, in a positively-slopedisolation structure an air gap is difficult to achieve because the TCDof the isolation structure is greater than the BCD.

Referring to FIG. 22, a perspective view of the device of FIG. 21 isillustrated, in accordance with some embodiments. Devices such astransistor 120 are formed in a top semiconductor layer 106 and areseparated by isolation structures 310 having negatively sloped sidewalls. Isolation structures 310 may be used in place of positivelysloped isolation structures without negatively impacting channel lengthor other aspects of transistor 120. A more effective isolation structureis therefore achieved. Because the TCD of the isolation structure 310may be the same as the TCD of a typically used isolation structure, again in isolation strength can be achieved in the same criticaldimension of the active devices 120. Isolation strength increases asdepth into the isolation structure 310 increases.

FIG. 23 illustrates a partial top down view of the devices of FIGS. 17,19, and 21, in accordance with some embodiments. It should be understoodthat the view of FIG. 23 may be part of a wafer. Isolation structure110, 210, or 310 surround devices 120 which include source/drain regions124, gate spacers 126, and gate electrode 128. The length of trenches 24(see FIG. 3) or trenches 44 (see FIG. 5) and the subsequently formedisolation structures formed therein may vary based on the design of thetransistor 120 or other formed devices. As seen in FIG. 23, isolationstructures 110, 210, or 310 may continue around the ends of the deviceregion 22. At the ends of device regions 22, isolation structures 110,210, or 310 may have negatively sloped sidewalls. In some embodiments,however, isolation structures 110, 210, or 310 may have substantiallystraight sidewalls or positively sloped sidewalls at the ends of deviceregion 22.

In some embodiments, the critical dimension of the devices may bedecreased due to increased isolation strength over traditionally formedisolation regions. In some embodiments, the critical dimension of thedevices using isolation structures 110, 210, or 310 may remain the sameas the critical dimension found in devices using traditionally formedisolation regions, but isolation is improved. In some embodiments, thecritical dimension of the devices using isolation structures 110, 210,or 310 may remain the same as the critical dimension found in devicesusing traditionally formed isolation regions. However, because isolationresulting from process embodiments is greater, less costly insulatingmaterials can be selected to achieve an isolation effect in isolationstructures 110, 210, or 310 which is comparable to the isolation effectachieved in traditionally formed isolation regions but with costlierinsulating materials. In other words, embodiments may use less costlyinsulating materials while achieving a similar isolation effect as intraditionally formed isolation regions.

FIG. 24 illustrates a partial cross-section of a transistor device 120which uses negatively sloped isolation structures, in accordance withsome embodiments. A channel 122 is formed from top semiconductor layer106. Isolation structures 110, 210, or 310 are provided on either sideof the device and extend at least partially into an insulator layer 104.Transistor 120 includes source/drain regions 124, source/drain silicideregions 125, gate spacers 126, gate dielectric 129, and gate electrode128. An ILD 140 is formed over transistor 120. Contacts (not shown) maybe formed through the ILD 140 to contact gate electrode 128 andsource/drain silicide regions 125.

A call out is provided which magnifies the interface between theisolation structures, source/drain regions, and source/drain silicideregions. The angle α is greater than 90°, representing that theisolation structure is negatively sloped. Observations of test devicesconsistent with the embodiments discussed herein (having a negativelysloped isolation structure) have shown improved isolation over devicesnot having a negatively sloped isolation structure.

Embodiments provide a way of improving isolation strength of anisolation structure in a device without having to choose strongerisolation materials at greater expense or without having to increasecritical dimension of the device. In some devices, isolation is moreimportant than in others, such as with RF devices. Embodiments provide anegatively sloped isolation structure that flares wider as it penetratesdeeper into a top semiconductor layer of an SOI base, thereby increasingisolation strength of the isolation structure as it goes deeper into thesurrounding material.

Although the embodiments have been described in terms of a semiconductordevice on an SOI substrate, one of skill will understand that aspects ofthis disclosure including a negatively sloped isolation region may beused in other device and substrate types.

One embodiment is a method including patterning a mask over asemiconductor layer of a substrate. A trench is etched through the mask,where the trench has a top opening having a first width and a bottomhaving a second width, where the second width is greater than the firstwidth. An insulating material is deposited in the trench, where theinsulating material flares from the first width to the second width.

Another embodiment is a method including etching a first trench and asecond trench in a semiconductor substrate, the first trench beingseparated from the second trench by a first device area of thesemiconductor substrate. An insulating material is deposited in thefirst trench and in the second trench to form a first isolationstructure and a second isolation structure, respectively, where an anglebetween a first sidewall of the first isolation structure and a topsurface of the first isolation structure is greater than 90°.

Another embodiment is a structure including a semiconductor materiallayer, a first isolation structure embedded in the semiconductormaterial layer, and a second isolation structure embedded in thesemiconductor material layer, where the first isolation structure andsecond isolation structure each have a top width and a bottom width,where the bottom width is greater than the top width. The structurefurther includes a device region of the semiconductor layer disposedbetween the first isolation structure and the second isolationstructure, where the device region has a device formed therein.

Another embodiment is a device including an insulating layer disposedover a substrate, and a semiconductor layer disposed over the insulatinglayer. A first isolation structure and a second isolation structure areembedded in the semiconductor layer, where each of the first isolationstructure and the second isolation structure extend into the insulatinglayer, and where each of the first isolation structure and the secondisolation structure have angled sidewalls. A first angle between anupper surface of the first isolation structure and a first adjoiningsidewall of the first isolation structure is less than 90 degrees. Adevice region disposed between the first isolation structure and thesecond isolation structure.

Another embodiment is a device including a film stack including aninsulator layer disposed over a substrate and a semiconductor layerdisposed over the insulator layer. A first set of isolation structuresis embedded in the film stack, where the first set of isolationstructures each have non-vertical sidewalls, an upper surface, and abottom surface, where a first width of the upper surface is greater thana second width of the bottom surface. A device region of thesemiconductor layer is laterally surrounded by the first set ofisolation structures.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A structure comprising: a semiconductor materiallayer; a first isolation structure embedded in the semiconductormaterial layer; a second isolation structure embedded in thesemiconductor material layer, wherein the first isolation structure andsecond isolation structure each have a top width and a bottom width,wherein the bottom width is greater than the top width; a thirdisolation structure embedded in the semiconductor material layer, thethird isolation structure having a top width and a bottom width, whereinthe top width of the third isolation structure is greater than thebottom width of the third isolation structure; and a device region ofthe semiconductor material layer disposed between the first isolationstructure and the second isolation structure, wherein the device regionhas a device formed therein.
 2. The structure of claim 1, furthercomprising: an insulator layer underlying the semiconductor materiallayer, wherein the first isolation structure extends below thesemiconductor material layer into the insulator layer.
 3. The structureof claim 2, wherein the first isolation structure extends completelythrough the insulator layer.
 4. The structure of claim 3, furthercomprising: a substrate underlying the insulator layer, wherein thefirst isolation structure extends into the substrate.
 5. The structureof claim 3, further comprising: an air gap embedded in the firstisolation structure.
 6. The structure of claim 1, wherein the firstisolations structure includes an air gap embedded therein, and whereinthe third isolation structure comprises a solid material throughout itsentirety.
 7. The structure of claim 1, wherein the first isolationstructure and the second isolation structure merge together at an end ofthe device region.
 8. The structure of claim 1, wherein an upper surfaceof the first isolation structure and the second isolation structureextend vertically higher than an upper surface of the semiconductormaterial layer.
 9. A device comprising: an insulating layer disposedover a substrate; a semiconductor layer disposed over the insulatinglayer; a first isolation structure and a second isolation structureembedded in the semiconductor layer, each of the first isolationstructure and the second isolation structure extending into theinsulating layer, each of the first isolation structure and the secondisolation structure having angled sidewalls, wherein a first anglebetween an upper surface of the first isolation structure and a firstadjoining sidewall of the first isolation structure is less than 90degrees; a third isolation structure embedded in the semiconductorlayer, the third isolation structure having a top surface level with atop surface of the first isolation structure, the third isolationstructure having a height less than a height of the first isolationstructure; and a device region disposed between the first isolationstructure and the second isolation structure.
 10. The device of claim 9,wherein the first isolation structure and the second isolation structureextend completely through the insulating layer.
 11. The device of claim10, wherein the first isolation structure and the second isolationstructure have a bottom surface embedded in the substrate.
 12. Thedevice of claim 10, wherein the first isolation structure and the secondisolation structure each have an air gap embedded therein.
 13. Thedevice of claim 9, wherein the third isolation structure has angledsidewalls, wherein a second angle between an lower surface of the thirdisolation structure and a second adjoining sidewall of the thirdisolation structure is less than 90 degrees.
 14. The device of claim 9,wherein the device region comprises a radio frequency (RF) device.
 15. Adevice comprising: a film stack comprising an insulator layer disposedover a substrate and a semiconductor layer disposed over the insulatorlayer; a first set of isolation structures embedded in the film stack,the first set of isolation structures each having non-verticalsidewalls, an upper surface, and a bottom surface, wherein a first widthof the upper surface is greater than a second width of the bottomsurface; a second set of isolation structures embedded in the filmstack, the second set of isolation structures each having non-verticalsidewalls, an upper surface, and a bottom surface, wherein for eachisolation structure in the second set of isolation structures, a thirdwidth of the upper surface is less than a fourth width of the bottomsurface; and a device region of the semiconductor layer laterallysurrounded by the first set of isolation structures.
 16. The device ofclaim 15, further comprising: a third set of isolation structuresembedded in the film stack, the third set of isolation structures eachhaving non-vertical sidewalls, the third set of isolation structureseach extending completely through the insulator layer, the third set ofisolation structures each having an air gap embedded therein.
 17. Thedevice of claim 15, wherein, for each isolation structure in the firstset of isolation structures, a ratio of a height of each to a width ofeach is between 0.5 and
 10. 18. The device of claim 15, wherein theratio is between 4 and
 10. 19. The device of claim 15, wherein the uppersurface of the each of the first set of isolation structures and theupper surface of each of the second set of isolation structures extendvertically higher than an upper surface of the semiconductor layer. 20.The device of claim 15, wherein the bottom surface of each of the firstset of isolation structures extends into the insulator layer below thesemiconductor layer.